PARTS MANUAL - BilJax · PARTS MANUAL B33-01-0094-05 . BOOM PERSONNEL LIFT This equipment is designed and manufactured in compliance ... Front Rest …

1

PARTS MANUAL

B33-01-0094-05

BOOM PERSONNEL LIFT

This equipment is designed and manufactured in compliance with the duties, responsibilities and standards set forth in the ANSI, CSA, AS and/or CE standards in effect at the time of manufacture.

This equipment will meet or exceed applicable ANSI, CSA, AS and/or CE codes and standards when operated in accordance with manufacturer’s recommendations.

It is the responsibility of the user to follow all regional codes and regulations that govern the safe operation of this equipment.

Obtain, read and obey all safety precautions before performing maintenance or repairs or attempting to operate this equipment. This includes all manufacturer recommendations as well as those directives set forth by government and local authorities.

To ensure proper and safe use of this equipment, it is strongly recommended that only trained and authorized personnel attempt to operate and maintain the boom lift.

This manual shall be considered a permanent and necessary component of the machine and shall be kept with the boom lift at all times.

Owners and Lessors should complete a full inspection of all components and perform a test of all functions, including brake functions, before commissioning or reselling the machine. Repair or replace all damaged or malfunctioning components.

Haulotte Group | BilJax, Inc. is dedicated to the continuous improvement of this and all Haulotte Group | BilJax products. Therefore, equipment information is subject to change without notice. Direct any questions or concerns regarding errors or discrepancies in this manual to the Haulotte Group | BilJax Service Department.

Copyright © Haulotte Group | BilJax, Inc. 2009. All Rights Reserved.

“Haulotte Group | BilJax” is a registered trademark and “A Step Above” and “Summit Series” are trademarks of Haulotte Group | BilJax, Inc. Contact Haulotte Group | BilJax for replacement manuals.

125 Taylor Parkway Archbold, Ohio 43502 Phone (800) 537-0540 (419) 445-8915 Fax (419) 445-0367

P/N: B33-01-0094-05

1

TABLE OF CONTENTS

Table of Contents 1

1 Replacement Decals 3

Legend: Safety Advisories 4

Before Operation 5

During Operation 5

Maintenance Safety 7

Damaged Equipment Policy 8

2 Replacement Parts 9

Outrigger 40

Towing 42

Front Rest 44

Brake And Axle 46

Slew Ring 48

Limit Switch 50

Control Compartment 52

Pump Compartment 54

Battery Compartment 56

Cover Assembly 58

Lower Boom 60

Triangle Weldment 62

Upper Boom 64

Jib Boom 66

Platform 68

Hydraulic Pump 70

Boom and Rotation Hydraulic Lines 74

Outrigger Hydraulic Lines 76

Water Line to Platform 77

Air Line to Platform 77

Wire Harnesses 78

Manual Platform Rotate 80

Material Lift Hook 82

Battery Layout 85

Drive & Set 86

Ordering Replacement Parts 88

2

3

1 REPLACEMENT DECALS

WARNING Decals contain information that is required for the safe and proper use of the aerial work platform.

Decals should be considered necessary components of the machine and should be checked before each use to verify that they are correctly attached and legible.

Promptly replace all decals that are no longer legible.

4

DECAL KIT - ANSI

5 — REPLACEMENT DECALS

5

DECAL KIT - ANSI B06-01-4010 DECAL KIT - Includes the following:

ITEM NO. PART NUMBER DESCRIPTION QTY.1 B06-00-0550 Decal - Warning - Unhitch To Operate 2 2 B06-00-0551 Decal - Caution - Latch / Jack / Brake 1 3 B06-00-0405 Decal - Warning - Hand Pinch Point 17 4 B06-00-0403 Decal - Emergency Lower Valve 4 5 B06-00-0521 Decal - Danger - Tip Over Hazard 7 6 B06-00-0404 Decal - Warning - Outrigger Crush Foot 8 7 B06-00-0161B Decal - 'Haulotte BilJax' - 5in Black / Red on Clear 2 8 B06-00-0477 Decal - Warning - Fork Lift Use 2 9 B06-00-0538 Decal - 3522A Transfer - Black 2

10 B06-00-0481 Decal - Caution - Transport Latch 2 11 B06-00-0535 Decal - Notice - Range of Motion - 3522A 2 12 B06-00-0482 Decal - Danger - Electrocution 2 13 B06-00-0037 Decal - "Lubricate Semi - Annually" 1 14 B06-00-0471 Decal - Danger - Main Instruction / Hazard - Platform 1 15 B06-00-0475 Decal - Warning - Read / Understand Manual 1 16 B06-00-0473 Decal - Notice - Operator Manual Missing 1 17 B06-00-0534 Decal - Warning - Platform Operation - Articulating 1 18 B06-00-0062 Decal - Notice - AC Power 2 19 B06-00-0530 Decal - Air - 120 PSI 2 20 B06-00-0531 Decal - Water - 3000 PSI 2 21 B06-00-0552 Decal - Notice - Lanyard Attachment 1 22 B06-00-0474 Decal - Notice - Platform Maximum Load 1 23 0202-0523 Decal - Flag, Made In USA 1 24 B06-00-0503 Decal - Notice - Handle Applications 1 25 B06-00-0504 Decal - Notice - Emergency Hand Pump 1 26 B06-00-0068 Decal - Notice - Low Foam Hydraulic Oil 1 27 B06-00-0494 Decal - Notice - Contains Hazardous Material 1 28 B06-00-0541 Decal - Caution - Manual Rotate / Retract 1 29 B06-00-0495 Decal - Caution - Compartment Access 2 30 B06-00-0505 Decal - Danger - Main Instruction / Hazard - Base 1 31 B06-00-0034 Decal - Danger - Battery / Charger Safety 1 32 B06-00-0533 Decal - Warning, Ground Operation Instructions - Articulating 2 33 B06-00-0484 Decal - Danger - Battery / Charger Instruction 1 34 B06-00-0543 Decal - Warning - Crush Hazard 2 35 B06-00-0496 Decal - Caution - Generator Plate Maximum 200 1 36 B06-00-0478 Decal - Notice - AC Power Connection 1 37 B06-00-0542 Decal - Warning - Maximum Tow Speed 65 1 38 B06-00-0544 Decal - Warning - Tow Hazard 65 mph 2

6

IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - ANSI

7

IDENTIFICATION PLATES & OPTIONAL EQUIPMENT – ANSI

IDENTIFICATION PLATES (Used on all standard equipment)

ITEM NO. PART NUMBER DESCRIPTION QTY.

39 B06-00-0526 Key Ring Tag 1 40 B06-00-0524 Annual Inspection Plate 1 41 B06-00-0490 VIN Plate 1 42 B06-00-0499 ANSI ID Plate 1

REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT – ANSI

ITEM NO. PART NUMBER DESCRIPTION QTY.43 B06-00-0529 Decal - Notice - Platform Rotate (Manual Rotation Option) 1 44 B06-00-0527 Decal - Warning - Drive and Set (Drive and Set Option) 1 45 B06-00-0528 Decal - Notice - Drive and Set (Drive and Set Option) 1 46 B06-00-0553 Decal - Warning - Jockey Wheel (Drive and Set Option) 1 47 B06-00-0485 Decal - Notice - Material Lift Set - up (Material Lift Option) 1 48 B06-00-0497 Decal - Notice - Material Lift Max 500 (Material Lift Option) 1 49 B06-00-0487 Decal - Notice - Unleaded Fuel Only (Gas Engine Option) 1 50 B06-00-0488 Decal - Caution - Component Damage (Gas Engine Option) 1 51 B06-00-0486 Decal - Notice - Engine Specifics (Gas Engine Option) 1 52 B06-00-0547 Decal - Warning - Eng Operate - Hot (Gas Engine Option) 1

8

DECAL KIT - CE

9

DECAL KIT - CE

B06-01-4020 DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY.

1 B06-00-0405-CE Decal - Warning - Hand Pinch Point 15 2 B06-00-0403-CE Decal - Notice - Emergency Lower 4 3 B06-00-0568-CE Decal - Caution - Outrigger Pressure 4 4 B06-00-0404-CE Decal - Warning - Outrigger Crush Foot 10 5 B06-00-0161B Decal - 'Haulotte BilJax' - 5in Black / Red on Clear 2 8 B06-00-0482-CE Decal - Danger - Electrocution 2

11 B06-00-0475-CE Decal - Warning - Read / Understand Manual 2 13 B06-00-0062-CE Decal - Notice - AC Power 2 14 B06-00-0173-CE Decal - Notice - Lanyard Attachment 1 15 B06-00-0474-CE Decal - Notice - Platform Maximum Load 1 16 0202-0523 Decal - Flag, Made In USA 1 17 B06-00-0068-CE Decal - Notice - Low Foam Hydraulic Oil 1 19 B06-00-0495-CE Decal - Caution - Compartment Access 2 20 B06-00-0572-CE Decal - Caution - Read Parts and Service Manual 1 21 B06-00-0034-CE Decal - Danger - Battery / Charger Safety 2 24 B06-00-0496-CE Decal - Caution - Generator Plate Maximum 200 1 26 B06-00-0542-CE Decal - Warning - Maximum Tow Speed 65 1

B06-01-4022 DECAL KIT - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY.

6 B06-00-0538-CE Decal - HTA 13 P - Black Clear Vinyl with Black Letters 2 7 B06-00-0537-CE Decal - Notice - Range of Motion - 3522A 2

B06-01-4021-DU DECAL KIT - Dutch - Includes the following: B06-01-4021-EN DECAL KIT - English International - Includes the following: B06-01-4021-FC DECAL KIT - French (Canadian) - Includes the following: B06-01-4021-FR DECAL KIT - French (European) - Includes the following: B06-01-4021-GE DECAL KIT - German - Includes the following: B06-01-4021-IT DECAL KIT - Italian - Includes the following: B06-01-4021-KO DECAL KIT - Korean - Includes the following: B06-01-4021-RU DECAL KIT - Russian - Includes the following: B06-01-4021-SW DECAL KIT - Swedish - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY.

9 B06-00-0037 Decal - "Lubricate Semi - Annually" 1 10 B06-00-0471 Decal - Danger - Main Instruction / Hazard - Platform 1 12 B06-00-0534 Decal - Warning - Platform Operation - 4527A 1 18 B06-00-0541 Decal - Caution - Manual Rotate / Retract 1 22 B06-00-0505 Decal - Danger - Main Instruction / Hazard - Base 1 23 B06-00-0533 Decal - Warning - Ground Operation 2 25 B06-00-0478 Decal - Notice - AC Power Connection 1

Note: Decals without the CE suffix are available in the following languages: -DE = German, -DU = Dutch, -FC = French (Canadian), -FR = French (European), -IT = Italian, -KO = Korean, RU = Russian, -SP = Spanish, -SW = Swedish To order add the appropriate suffix to the end of the part number.

10

IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - CE

11

IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - CE

IDENTIFICATION PLATES (Used on all standard CE equipment) ITEM NO. PART NUMBER DESCRIPTION QTY.

27 B06-00-0499-CE ID Plate 1

28 B06-00-0490 VIN Plate 1 DECALS FOR OPTIONAL EQUIPMENT - CE ITEM NO. PART NUMBER DESCRIPTION QTY.

29 B06-00-0529 Decal - Notice - Platform Rotate (Manual Rotation Option) 1 30 B06-00-0527 Decal - Warning - Drive and Set (Drive and Set Option) 1 31 B06-00-0528 Decal - Notice - Drive and Set (Drive and Set Option) 1 32 B06-00-0530 Decal - Air - 120 PSI (Air Line to Platform Option) 2 33 B06-00-0531 Decal - Water - 3000 PSI (Water Line to Platform Option) 2 34 B06-00-0553 Decal - Warning - Jockey Wheel (Drive and Set Option) 1 35 B06-00-0487 Decal - Notice - Unleaded Fuel Only (Gas Engine Option) 1

12

DECAL KIT - AUSTRALIA

13

DECAL KIT – AUSTRALIA

B06-01-4020 DECAL KIT - Includes the following:

ITEM NO. PART NUMBER DESCRIPTION QTY.1 B06-00-0405-CE Decal - Warning - Hand Pinch Point 15 2 B06-00-0403-CE Decal - Notice - Emergency Lower 4 3 B06-00-0568-CE Decal - Caution - Outrigger Pressure 4 4 B06-00-0404-CE Decal - Warning - Outrigger Crush Foot 10 5 B06-00-0161B Decal - 'Haulotte BilJax' - 5in Black / Red on Clear 2 8 B06-00-0482-CE Decal - Danger - Electrocution 2

11 B06-00-0475-CE Decal - Warning - Read / Understand Manual 2 13 B06-00-0062-CE Decal - Notice - AC Power 2 14 B06-00-0173-CE Decal - Notice - Lanyard Attachment 1 15 B06-00-0474-CE Decal - Notice - Platform Maximum Load 1 16 0202-0523 Decal - Flag, Made In USA 1 17 B06-00-0068-CE Decal - Notice - Low Foam Hydraulic Oil 1 19 B06-00-0495-CE Decal - Caution - Compartment Access 2 20 B06-00-0572-CE Decal - Caution - Read Parts and Service Manual 1 21 B06-00-0034-CE Decal - Danger - Battery / Charger Safety 2 24 B06-00-0496-CE Decal - Caution - Generator Plate Maximum 200 1 26 B06-00-0542-CE Decal - Warning - Maximum Tow Speed 65 1

B06-01-4022 DECAL KIT - Includes the following:

ITEM NO. PART NUMBER DESCRIPTION QTY.6 B06-00-0538-CE Decal - HTA 13 P - Black Clear Vinyl with Black Letters 2 7 B06-00-0535-CE Decal - Notice - Range of Motion - 3522A 2

B06-01-4021- EN DECAL KIT - English International - Includes the following: ITEM NO. PART NUMBER DESCRIPTION QTY.

9 B06-00-0037 Decal - "Lubricate Semi - Annually" 1 10 B06-00-0471 Decal - Danger - Main Instruction / Hazard - Platform 1 12 B06-00-0534 Decal - Warning - Platform Operation - 4527A 1 18 B06-00-0541 Decal - Caution - Manual Rotate / Retract 1 22 B06-00-0505 Decal - Danger - Main Instruction / Hazard - Base 1 23 B06-00-0533 Decal - Warning - Ground Operation 2 25 B06-00-0478 Decal - Notice - AC Power Connection 1

14

IDENTIFICATION PLATES & OPTIONAL EQUIPMENT – AUSTRALIA

15

IDENTIFICATION PLATES & OPTIONAL EQUIPMENT - AUSTRALIA

IDENTIFICATION PLATES (Used on all standard equipment)


27 B06-00-0524 Annual Inspection Plate 1

28 B06-00-0490 VIN Plate 1

29 B06-00-0499 ANSI ID Plate 1

REPLACEMENT DECALS FOR OPTIONAL EQUIPMENT - AUSTRALIA


30 B06-00-0529 Decal - Notice - Platform Rotate (Manual Rotation Option) 1

31 B06-00-0527 Decal - Warning - Drive and Set (Drive and Set Option) 1

32 B06-00-0528 Decal - Notice - Drive and Set (Drive and Set Option) 1

33 B06-00-0530 Decal - Air - 120 PSI (Air Line to Platform Option) 2

34 B06-00-0531 Decal - Water - 3000 PSI (Water Line to Platform Option) 2

35 B06-00-0553 Decal - Warning - Jockey Wheel (Drive and Set Option) 1 36 B06-00-0487 or

B06-00-0498 Decal - Notice - Unleaded Fuel Only (Gas Engine Option)or Decal - Notice - Diesel Fuel Only (Gas Engine Options)

1

37 B06-00-0547 Decal - Warning - Eng Operate - Hot (Gas Engine Option) 1

16

17

2 REPLACEMENT PARTS

Use only parts manufactured and/or authorized by Haulotte Group | BilJax, Inc. when replacing damaged components. See page 66 for replacement part ordering information.

Only personnel properly trained and authorized to operate all equipment and familiar with all boom functions should attempt to repair or replace any part of the boom lift.

Always read, understand and obey all safety precautions included in this manual, as well as those precautions attached to the lift and dictated by federal, state and local regulations.

18

OUTRIGGER ASSEMBLY

19

OUTRIGGER ASSEMBLY PARTS LIST

Item No. Part No. Description Qty.

1 A-01120 Outrigger Weldment 1

2 A-00046 Grommet, 1.5 x 1.25 x 1.75 1

3 A-00031 Bearing 2

4 A-00058 Pin, 1.0 x 5.25 (Front Outriggers Only) 1

5 A-00018 Pin Retainer (Front Outriggers) Pin Retainer (Rear Outriggers)

4 5

6 0096-0016 Cap Screw, M10 x 25 (Front Outriggers) Cap Screw, M10 x 25 (Rear Outriggers)

4 5

7 0096-0041 Hex Nut, Self-Locking, M10 (Front Outriggers) Hex Nut, Self-Locking, M10 (Rear Outriggers)

4 5

8 A-00060 Pin, 1.0 x 4.0 1

9 A-01138 Outrigger Hydraulic Cylinder 1

B02-04-0118 Valve, Cylinder 1

B01-08-0022A Coil, Cylinder 1

10 A-00141 Outrigger Cylinder Guard 1

11 0096-0009 Cap Screw, M8 x 10 2

12 A-00142 Guard Slide 1

13 0096-0011 Cap Screw, M8 x 25 2

14 0096-0040 Hex Nut, Self-Locking, M8 9

15 A-00154 Spring, Outrigger Sensor 1

16 0096-0036 Cap Screw, M16 x 150 1


18 0096-0051 Cap Screw, M16 x 100 1

19 A-00128 Pad Mount Weldment 1

20* B01-03-0078 Limit Switch Assembly – ANSI 1

21* 0090-0232 Slotted Machine Screw, #10-24 x 5/8 2

22* 0090-0182 Hex Nut, Self-Locking, #10-24 2

23 A-01136 Foot Pad, Aluminum, 10” 1

24 A-01137 Foot Pad Bottom, 10” 1

25 0096-0121 Flat Head Cap Screw, M8 x 30 4

26 A-00135 Foot Pad Ball 1

27 A-00195 O-Ring, Foot Pad 1


29 A-01127 Foot Pad Lock 2

30 A-00139 Foot Pad Cap 1

31 B20-00-0019 Bumper 1

32 A-00086 Pin, 1.0 x 5.44 (Front Outriggers) Pin, 1.0 x 5.44 (Rear Outriggers)

1 2

CE Limit Switch Assembly Parts List* For CE machines, Item 20 is replaced by 1 of A-03631 and 1 of A-03632; Item 21 is replaced by 2 of 0090-0692; Item 22 is replaced by 2 of 0090-0181.

NOTE: All quantities specified above are per outrigger.

20

TOWING ASSEMBLY

1

2

3

4

5

6

7

8

9

1011

12

13

14

15

1617

18 19 20

2

4

21

4

22

23

24

25

26

27

28

21

TOWING ASSEMBLY PARTS LIST


1 B03-00-0017 Safety Chain Assembly 2

2 0096-0025 Cap Screw, M12 x 120 4

3 0096-0046 Washer, Flat, M12 2


5 A-02177 Brake Bracket 1

6 A-00192 Brake Lever 1

7 0096-0010 Cap Screw, M8 x 20 4


9 A-01154 Tongue Handle 1

9 A-03662 Tongue Handle – CE 1

10 A-00144 Jack Assembly 1

11 A-02166 Attach Plate 1

12 0096-0087 Washer, Flat, M20 2

13 A-02160 Jack Weldment 1

14 A-02164 Axle 1

15 A-02165 Tire and Wheel Assembly 2

16 0090-0147 Cotter Pin, 1/8 – 1 1/4 2

17 B12-00-0211 Hitch Coupler 1

17 A-03616 Bradley Coupler – CE 1

18 B04-06-0033 Washer, Flat, Brake Lever 1

19 B04-00-0088 Clevis Pin, Brake Lever 1

20 B04-00-0089 Cotter Pin, Brake Lever 1

21 0096-0022 Cap Screw, M12 x 75 1

22 0096-0075 Cap Screw, M10 x 120 4


24 B12-00-0211 Combination Hitch Coupler (Optional; Inset) 1

25 0090-0878 Cap Screw, #5/8-11 x 4 3/4 2

26 0090-0425 Washer, 5/8 4

27 0090-0194 Hex Nut, Self-Locking, 5/8-11 2

28 B12-00-0066 Adjustable Coupler – 2” Ball 1

22

FRONT REST ASSEMBLY

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1617

18

19

20

21

22 23

6

15

23

FRONT REST ASSEMBLY PARTS LIST


1 A-01145 Front Rest Weldment 1

2 0096-0024 Cap Screw, M12 x 100 2


4 A-00157 Front Rest Pad 8

5 0096-0017 Cap Screw, M10 x 30 16


7 A-00159 Boom Latch 1

8 0096-0016 Cap Screw, M10 x 25 4

9 A-00169 Switch Bracket 1

10 0096-0002 Cap Screw, M6 x 20 2


12 A-00188 Switch Cam 2

13 0096-0106 Cap Screw, M4 x 40 3


15 B01-03-0078 Limit Switch Assembly, NO (Female) 1

16 B01-03-0079 Limit Switch Assembly, NC (Male) 1

17 0090-0709 Machine Screw, #6-32 x 1 1/4 2

18 0090-0180 Hex Nut, Self-Locking, #6-32 2

19 A-00158 Tension Spring 1

20 0096-0038 Cap Screw, M20 x 120 2


22 B01-10-0239 Grommet, Marker Light 2

23 B01-10-0297 Marker Light, Amber 2

23 A-03633 Marker Light, White – CE 2

24 A-00190 Switch Cam Spacer 3

A-05660 Tongue Tube Weldment – CE 1

A-05655 Bike Catcher Weldment – CE 2

0096-0025 Cap Screw, M12 x 120 2

0096-00 Cap Screw, M12 x 4

0096-0042 Hex Nut, Self-Locking, M12 6

24

BRAKE AND AXLE ASSEMBLY

4 5

1

2

3

7

6

8

9

10

11

12

13 14

15

1716

7

8

7 18

19

20

21

25

BRAKE AND AXLE ASSEMBLY PARTS LIST


1 A-01171 Axle Mount Weldment 1

2 A-00143 Fender 2

3 A-00184 Equalizer Bracket 1

4 A-00151-1 Fender Mount – Left 1

5 A-00151-2 Fender Mount – Right 1

6 0096-0014 Cap Screw, M10 x 20 8


8 0096-0016 Cap Screw, M10 x 25 24

9 0096-0010 Cap Screw, M8 x 20 3

10 A-01179 Brake Cable Mount 1

11 A-01175 Axle – US/CAN 1

11 A-04618 Axle – CE 1


13 0096-0034 Cap Screw, M16 x 40 4

14 0096-0050 Washer, M16 8


16 A-00489L Brake Assembly – Left 1

17 A-00489R Brake Assembly – Right 1

18 B21-00-0031 Brake Drum Assembly 2

19 B08-02-0024 Wheel Assembly – 75 R14C 2

19 A-04617 Tires – ST205 70 R15 – CE 2

20 0090-1075 Lug Nut, 1/2-20, Chrome 10

21 A-01187 Cable Assembly – Parking Brake 1

MECHANICAL BRAKE ASSEMBLY – CE

A-03658 Brake Link Weldment – CE 1

A-03626 Brake Link Coupler – CE 1

A-03628 Brake Link Rod – CE 2

A-03665 Brake Cable Guide 1

A-03669 Bolt, M10 x 50 1

A-05670 Brake Cable 1

A-03630 Brake Slide 2

26

SLEW RING ASSEMBLY

12

3

4

5

6

7

8

9

10

11

12

13 14

15

14

27

SLEW RING ASSEMBLY PARTS LIST


1 A-01189 Slew Assembly and Adapter 1

2 Slew Ring 1

3 Slew Ring Drive 1

4 A-01149 Base Ring Adapter 1

5 0090-0461 Cap Screw, 1/2-13 x 2 2

6 0090-0212 Lock Washer, 1/2 2



9 0090-0643 Cap Screw, 5/8-11 x 2-3/4, Grade 8 12


11 A-01352 Rotation Ring 1

12 A-01356 Ring Stop Weldment 1

13 A-01365 Wire Ring Weldment 1

14 0096-0008 Cap Screw, M6 x 30 4


28

LIMIT SWITCH ASSEMBLY

1

2

345

6

7

8

9

10

11

12

13

14

15

11 17

18 19 20

29

LIMIT SWITCH ASSEMBLY PARTS LIST


1 A-01190L Switch Plate – Left 1

2 A-01190R Switch Plate – Right 1

3 0096-0016 Cap Screw, M10 x 25 4

4 B01-03-0078 Limit Switch NO 1

5 B01-03-0079 Limit Switch NC 1

6 A-01191 Switch Cam Weldment 1

7 A-01195 Switch Cam Top Slide 1



10 0096-0078 Cap Screw, M6 x 80 1


12 0096-0085 Cap Screw, M6 x 60 1

13 0090-0232 Machine Screw, #10-24 x 5/8 4

14 0090-0182 Hex Nut, Self-Locking, #10-24 4

15 0096-0081 Cap Screw, M8 x 80 2

16 A-01157 Switch Slide (Not Pictured) 2


18 0096-0017 Cap Screw, M10 x 30 4

19 A-01197 Jib Slide Pad 2


30

CONTROL COMPARTMENT ASSEMBLY

1

3

4

2 5

6

7

8

9

10

11

12

13

14

15

7

13

8 7 17 18 19 2016

7

7

7

8

7 21

8

31

CONTROL COMPARTMENT ASSEMBLY PARTS LIST


1 A-00712 Lower Control Box 1

2 A-00233 Lower Control Mount 1

3 A-00290 Cover Stop Bracket 1

4 0096-0016 Cap Screw, M10 x 25 2


6 A-00259 Level Sensor 1

7 0096-0002 Cap Screw, M6 x 20 21


9 A-00287 Mount Plate – GFI Outlet 1

10 A-00255 Motor Controller 1

11 A-01232 Battery Charger 1

12 A-00251 Gas Spring 1

13 0090-0920 Stud Ball, 10mm 2

14 0090-0185 Hex Nut, Self-Locking, 5/16-18 2

15 A-01200 Turntable Weldment 1

16 B01-10-0046 Outlet Box 1

17 B01-10-0034 GFI Outlet 1

18 B01-10-0035 Outlet Box Cover 1

19 0096-0001 Cap Screw, M6 x 16 2

20 A-00288 Plastic Cover 1

21 A-01232 Battery Charger (Alternate) 1

32

PUMP COMPARTMENT ASSEMBLY

1

2

3

4

5

6

7

4

33

PUMP COMPARTMENT PARTS LIST


1 A-00268 Tire Iron/Jack Handle 1

2 B04-07-0033 Clamp 2

3 0096-0001 Cap Screw, M6 x 16 2


5 A-00290 Cover Stop Bracket 1

6 0096-0002 Cap Screw, M6 x 20 2

7 0096-0014 Cap Screw, M10 x 20 3

34

BATTERY COMPARTMENT ASSEMBLY

1

3

4

5

6

7

11

14

15

16

17

28 9 10 1312

8

22

24

23

21

25

19

18

20

26 27

29

28

35

BATTERY COMPARTMENT ASSEMBLY PARTS LIST


1 A-00215 Battery Box Weldment – Left 1

2 A-00220 Battery Box Weldment – Right 1

3 A-00278 Battery Hinge Pin 2

4 0096-0050 Washer, Flat, M16 8

5 0090-0147 Cotter Pin 4

6 A-00271 Battery Clamp 4

7 0096-0010 Cap Screw, M8 x 20 4


9 A-01219 Battery Box Latch – Left 1

10 A-01220 Battery Box Latch – Right 1

11 A-00229 Latch Plate 2

12 A-00234 Spacer 2

13 0096-0011 Cap Screw, M8 x 25 4


15 A-01225 Nose Weldment 1

16 0096-0014 Cap Screw, M10 x 20 4


18 A-00037 Ramp, Short 2



21 A-00253 Grommet 3

22 B04-07-0036 Clamp 2

23 B01-09-0132 A-Frame Handle, Connector 1

24 B01-09-0131 Plug, Connector 1

25 A-01272 Battery Cable Kit 1

26 B01-09-0133 Terminal Boot – Black 4

27 B01-09-0134 Terminal Boot – Red 4

28 A-00242 Battery 4

29 0090-0162 Hex Nut, 3/8-16 8

36

COVER ASSEMBLY

37

COVER ASSEMBLY PARTS LIST


1 A-01240 Cover – Left 1

2 A-01239 Cover – Right 1

3 A-01230 Cover Brace 2

4 A-00252 Hinge 4

5 0096-0002 Cap Screw, M6 x 20 12


7 0090-1080 Pop Rivet 22

8 A-00284 Controls Cover – Left Side w/Hinge 1

9 A-00292 Cover Latch Assembly 2

38

LOWER BOOM ASSEMBLY

1

2

3

4

5

6

7 8

9

10

11

12

5

6

6

12

12

6 6

5

5 5

6

11

13

14

15

39

LOWER BOOM ASSEMBLY PARTS LIST


1 A-01300 Lower Boom Weldment 1

2 A-01314 Lower Link Weldment 1

3 A-01551 Lift Cylinder 1

4 A-00159 Boom Latch 1

5 0096-0016 Cap Screw, M10 x 25 8


7 A-00157 Rest Pad 3

8 0096-0017 Cap Screw, M10 x 30 6

9 A-00021 Pin, 1.25 x 8.5 1

10 A-00019 Pin Retainer, 1.25 2

11 A-00049 Pin, 1.0 x 8.5 2

12 A-00018 Pin Retainer, 1.0 3

13 A-00031 Bearing 2

14 A-00059 Pin, 1.0 x 7.0 1


40

TRIANGLE WELDMENT ASSEMBLY

1

2

3

4

6

7

8

9

10 11

4

5

5

6

6

6

6

9

7

127 9

8

8

7

8

7

6

13

147 15

15

14

41

TRIANGLE WELDMENT ASSEMBLY PARTS LIST


1 A-01320 Triangle Weldment 1

2 A-01552 Master Cylinder 1

3 A-01555 Lift Cylinder – Upper 1

4 A-00021 Pin, 1.25 x 8.5 2


6 0096-0016 Cap Screw, M10 x 25 8



9 A-00049 Pin, 1.0 x 8.5 3

10 A-00537 Switch Block 1

11 0096-0049 Cap Screw, M8 x 45 2



14 A-00059 Pin, 1.0 x 7.0 2


42

UPPER BOOM ASSEMBLY

7 2 6 8

8

9

3

6

6

6

6

5

4

6

1

9

10

10

11

20

22

22

22

21

19

1919 15

17 17A

18

18181312

14

16

43

UPPER BOOM ASSEMBLY PARTS LIST


1 A-01502 Upper Boom Weldment 1

2 A-01510 Telescopic Boom Tube 1

3 A-01550 Extension Cylinder 1

4 A-00535 Slider 2

5 0096-0017 Cap Screw, M10 x 30 4



8 A-00533 Wear Pad 12

9 A-00534 Wear Pad Shim 8

10 0096-0013 UHMW Bolts, M10 x 15 24

11 A-00532 Tube Slider 1

12 A-00529 Tube Slider Back 1

13 0096-0018 Cap Screw, M10 x 40 4

14 A-01554 Boom Latch Hook 1

15 A-01531 Cable Track Tube 1

16 A-01536 Cable Track Tray 1

17

17A

A-01530

A-01520

Cable Track, Dual Piece Mounting, Both Ends (Prior to June 2010)

Cable Track, Single Piece Mounting, Both Ends (June 2010 onwards). Also uses: 0096-0012 M8 x 25 Flat Head Cap Screw (Qty of 2) to attach to Item 16

1

18 0096-0010 Cap Screw, M8 x 20 (Qty used decreases by 6 when 17A is used)

12

19 0096-0040 Hex Nut, Self-Locking, M8 (Qty used decreases by 4 when 17A is used)

12

20 A-00059 Pin, 1.0 x 7.0 1


22 0096-0016 Cap Screw, M10 x 25 7

44

JIB BOOM ASSEMBLY

2

3

5

6

7 8

1

7 12 13

11

8

10

9

13

4

15

8

14

7

16

18

17

15

7

22

21 23 1920

2425

27

26

15

8

14

7

8

8

28

29

30

31

31

45

JIB ASSEMBLY PARTS LIST


1 A-00657 Jib Link Weldment 2

2 A-00651 End Pivot Weldment 1

3 A-00660 Jib Cylinder 1

4 A-01553 Slave Cylinder 1

5 A-00662 Jib End Weldment 1

6 A-01979 Bulkhead – Left 1

7 0096-0016 Cap Screw, M10 x 25 7



10 A-00054 Pin Retainer, 1.0, Flat Head 2

11 A-00052 Pin, 1.0 x 5.25 1


13 A-00061 Pin, 1.0 x 7.375 2

14 A-00925 Pin Retainer, 0.75 4

15 A-00050 Pin, 0.75 x 7.375 4

16 A-00674 Valve Guard 1

17 A-00667 Jib Bumper 1


19 B01-10-0046 Outlet Box 1

20 B01-10-0034 GFI Outlet 1

21 B01-10-0035 Outlet Box Cover 1

22 0096-0001 Cap Screw, M6 x 16 2


24 A-00522 Boom End Weldment 1


26 A-00038 Ramp, 0.25 4


28 0096-0019 Cap Screw, M12 x 25 8


30 0096-0018 Cap Screw, M10 x 40 2


46

PLATFORM ASSEMBLY

1

2

3

4

5

6 7

8

9

10

11

12

13

4

5

14

15

16

17

19 20 212223

24

25

25

13

1326

18

28

29

27

3031

47

PLATFORM ASSEMBLY PARTS LIST


1 A-00450 Platform Weldment 1

2 A-00713 Platform Control Box 1

3 A-00461 Upper Control Box Mount 1

4 0096-0016 Cap Screw, M10 x 25 4


6 A-00466 Control Box Latch 1

7 0090-1088 Rivet 2

8 A-00462 Spool 3


10 A-00463 Midrail End 4

11 0096-0052 Cap Screw, M6 x 40 2

12 0096-0115 Socket Head Cap Screw, M6 x 20 2


14 A-00464 Midrail 1

15 A-00468 Manual Mounting Plate 1

16 A-00467 Manual Storage Box 1

17 A-00071 Pin 1

18 A-00486 License Bracket 1

19 A-00487 Tail Light Box 2

20 B01-10-0239 Grommet, Marker Light 2

21 B01-10-0238 Marker Light, Red 2

22 B01-10-0236 Grommet, Tail Light 2

23 B01-10-0235 Tail Light 2

24 B01-10-0240 License Plate Lamp 1

25 0096-0002 Cap Screw, M6 x 20 2

26 0096-0079 Cap Screw. M6 x 100 6

27 A-00474 Cord Wrap 1

28 A-00071 Pin, 0.5” x 8.875” 1

29 0090-0147 Cotter Pin 2

30 A-00488 Skid Pad 1

31 0096-0080 Flat Head cap Screw, M8 x 70 4


48

PUMP ASSEMBLY (A-01254)

1

2

3

5

6

7

89

10

11

12

13

14

15

21

21

24

19

17

17

17

24

17

19

22

17

19

23

17

17

20

4

19

17

20

19

17

16

20

25

18

49

PUMP ASSEMBLY PARTS LIST


1 B02-15-0496 Manifold, Valve Housing 1

2 B02-14-0108 Valve, Cartridge (Telescope) 2

3 B02-15-0472 Manual Pump, Extend/Retract/Rotate 1

4 B02-14-0089 Valve, Cartridge (Outrigger Check) 1

5 B02-14-0109 Valve, Cartridge (Outrigger) 2

6 B02-14-0091 Valve, Check 1

7 B02-14-0110 Valve, Check 1

8 B02-14-0094 Valve, Proportional 1

9 B02-14-0095 Coil Sterling, Proportional Valve 1

10 B02-14-0111 Valve, Relief 1

11 B02-14-0097 Valve, Relief 1

12 B02-14-0098 Valve, Shuttle 1

13 B02-14-0099 Valve, Cartridge (Rotator) 1

14 B02-14-0100 Valve, Counterbalance 2

15 B02-14-0101 Valve, Cartridge (Basket Compensate) 1

16 B02-14-0114 Valve, Flow Control (Rotator) 1

17 B02-02-0245 Fitting, Plug, #2 ORB 11

18 B02-02-0246 Fitting, Hex Plug 1


20 B02-14-0112 Coil, 20 VDC, #8 5

21 B02-14-0113 Coil, 20 VDC, #10 4

22 B02-15-0497 Stud, #1/4-20 x 5/8 4

23 B02-15-0498 Expansion Plug 1


25 B02-15-0478 Seal Ring 1

50

PUMP ASSEMBLY, CONTINUED

1

23

4

5

6

7

8 9

10

11

12

13

14

15

16

17

18

15

19

20

21

22

51

PUMP ASSEMBLY PARTS LIST, CONTINUED


1 B02-15-0499 Reservoir 1

2 B02-15-0470 Pump Assembly, 2.09CCM 1

3 B02-15-0471 Motor, Pump, 24 V DC 1

4 B02-15-0500 Coupling, .875 x 2.795 1

5 B02-15-0501 Filter, Hydraulic 1

6 B02-15-0476 Sight Glass 1

7 B02-15-0477 Socket Head Cap Screw, M8 x 85 2

8 B02-02-0247 Fitting, Plug, M14 x 1.5 x 5.8 1

9 B02-15-0478 Seal Ring 1

10 B02-15-0502 Hose Clamp, 15/32 (12mm) 4

11 B02-15-0480 Filter, Suction, Pump 1

12 B02-15-0504 Allen Nut, 1/4-20 4

13 B02-02-0255 Fitting, M18 x HB-90 MxHB-90 1

14 B02-15-0503 O-Ring, 110.72 x 3.53 NBR 70D 1

15 B02-02-0279 Fitting, JIC-8 x Push On FsxPO 2

16 B02-15-0505 Hose, Black, 1/2 x 6” 1

17 B02-02-0280 Fitting JIC-8 x #6 90 MxM 1

18 B02-15-0506 Cap Screw, #5/16-18 x 1 1/4 2

19 B02-02-0278 Fitting, JIC-8 x #12 MxM ORB 1


21 B02-02-0282 Fitting, 3/8 NPT x 1/2 MxHB 1

22 B02-15-0507 Hose, Black, 1/2 x 15” 1

B02-02-0276 Fitting, Plug, #8 ORB (Under Reservoir) 1

52

BOOM AND ROTATION HYDRAULIC LINES

53

BOOM AND ROTATION HYDRAULIC LINES PARTS LISTS

Item No. Part No. Description

1 B02-01-0283 #4 x 32” Hydraulic Hose
























FITTINGS

Part No. Description Qty.

B02-02-0259 #6 MORFS - #6 MORB, STR 11

B02-02-0264 #6 MORFS - # 6 MORB, 45º 7

B02-02-0260 #6 MORFS - #6 MORB, 90º 1

B02-02-0237 #4 MORFS - #6 MORB, STR 2

B02-02-0262 #6 MORFS - #10 MORB, 45º 2

B02-02-0258 #6 MORFS, Tee 5

B02-02-0270 #6 MORFS - #6 MORFS - #6 MORB, Tee 1

B02-02-0196 #4 MORB - #2 MNPT, STR 1

B02-02-0242 #2 QD Plug 1

B02-02-0241 #2NPTFM Coupling 1

54

OUTRIGGER HYDRAULIC LINES

OUTRIGGER HYDRAULIC LINES PARTS LIST


1 B02-01-0325 #4 x 24” Hydraulic Hose 4








9 B02-01-0258 Fitting, Tee, #6 MORFS 6

10 B02-01-0259 Fitting, #6 MORFS - #6 MORB 8

55

WATER LINE TO PLATFORM (OPTION A-01701)

Part No. Description

B09-00-0039 #6 x 126” W/1-6-6FMP, 1-6-6MP 3000 PSI Pressure Washer Hose

B09-00-0040 #6 x 420” W/2-6-6MPSW 3000 PSI Pressure Washer Hose

B09-00-0041 #6 x 78” W/1-6-6FMP, 1-6-6MP 3000 PSI Pressure Washer Hose

B09-00-0032 Fitting, QD E Series FM-#6FMNPT

B09-00-0033 Fitting, QD E Series M-#6FMNPT

AIR LINE TO PLATFORM (OPTION A-01700)


B09-00-0034 #6 x 126” W/1-6-6FMPSW, 1-6-6MP 300 PSI Air Hose

B09-00-0035 #6 x 420” W/2-6-6MP 300 PSI Air Hose

B09-00-0046 #6 x 78” W/1-6-6FMPSW, 1-6-6MP 300 PSI Air Hose

B02-02-0108 Fitting, #6FMNPT-#4FMNPT STR

B09-00-0025 Fitting, Univ QD FM-#4MNPT

B09-00-0026 Fitting, QD IND Series M-#4MNPT

B09-00-0027 Fitting,QD ARO Series M-#4MNPT

B09-00-0028 Fitting, Univ QD FM-#6FMNPT

B09-00-0029 Fitting, QD DF Series M-#6FMNPT

B09-00-0030 Fitting, QD J Series M-#6FMNPT

56

WIRE HARNESSES

57

WIRE HARNESSES AND KITS – ANSI


A-01153 Light Kit – Trailer

A-01182 Hose Kit – Trailer (See Page 76)

A-01187 Brake Cable (Hydraulic Surge)

A-01246 Tail Light Kit – Cage

A-01269 Hose Kit – Boom (See Page 74-75)

A-01272 Battery Cable Kit

A-01714 Comm Wire

A-01715 Analog Harness

A-01717 Outrigger Coil/Switch Harness

A-01718 Power Harness

A-01722 110v Tower-to-Platform Wire

A-01723 Taillight Harness – Tower-to-Platform

A-01724 Secondary Cylinder Wire

A-01725 Jib Wire

A-01726 110v Trailer-to-Tower Wire

B21-00-0028 Brake Line Kit

WIRE HARNESSES AND KITS – CE


A-05670 Brake Cable – CE

A-05673 Taillight Harness – Tower-to-Platform – CE

A-05674 Light Kit – Trailer – CE

A-05682 Tail Light Kit – Cage

58

MANUAL PLATFORM ROTATE ASSEMBLY (OPTION A-00300)

59

MANUAL PLATFORM ROTATE ASSEMBLY PARTS LIST


1 A-00301 Platform Mount A Weldment 1

2 A-00308 Platform Mount Weldment 1

3 A-00315 Gearbox – Platform Rotate 1

4 A-00330 Bearing – .75” ID 2

5 A-00329 Pin – 0.75 x 10.25 DB 1

6 A-00017 Pin Retainer – 0.75 2

7 0096-0014 Cap Screw, M10 x 20 6


9 0096-0019 Cap Screw, M12 x 25 2


11 A-00071 Pin, Platform 1

12 0090-0147 Cotter Pin 2

13 0096-0103 Cap Screw, M8 x 140 2


60

MATERIAL LIFT HOOK ASSEMBLY (OPTION A-01846)

1

2

3

45

6

7

8

9

1011

1213

15

16

17

18

4

14

19

61

MATERIAL LIFT ASSEMBLY PARTS LIST


1 A-01977 Platform Mount Weldment – LS 1

2 A-00982 Load Sense Weldment 1

3 0096-0055 Cap Screw, M12 x 190 1


5 A-00988-1 Load Cell 1

6 0096-0089 Cap Screw, M12 x 65 2

7 A-00990A Load Sense Spacer A 1

8 A-00990B Load Sense Spacer B 2

9 0096-0069 Cap Screw, M10 x 75 1



12 A-00994 LS Roller Bar 1

13 A-00995 LS Roller 2

14 0096-0046 Washer, Flat, M12 4

15 0090-0147 Cotter Pin 2

16 0096-0009 Cap Screw, M8 x 10 2

17 A-00038 Ramp 4



20 A-00992 Load Sense Interface (Not Pictured) 1

21 0096-0085 Cap Screw, M6 x 60 3


62

MATERIAL LIFT ASSEMBLY, CONTINUED

MATERIAL LIFT HOOK PARTS LIST


1 A-00480 Material Lift Weldment 1

2 A-00155 Lift Hook Storage Bracket 1

3 A-01156 Bracket Clamp 1

4 A-00028 Pin 1

5 A-00485 Lift Hook Assembly 1

6 A-00037 Ramp, Short 4



9 0096-0016 Cap Screw, M10 x 25 2


11 0096-0029 Cap Screw, M12 x 220 1


A-01976 Load Sense Module (Not Pictured) 1

63

BATTERY LAYOUT

3522A BATTERY LAYOUT (Kit A-01272)

Item No. Description

1 30” Red, 2 Gauge, 5/16” Ring – Lug

2 37” Black, 2 Gauge, 5/16” Ring – 5/16” Ring

3 8” Black, 2 Gauge, 5/16” Ring – 5/16” Ring (Qty. 2)

4 15” Black, 2 Gauge, 5/16” Ring – Lug

5 24” Red, 2 Gauge, 5/16” Ring – Lug

6 48” Black, 2 Gauge, 5/16” Ring – Lug

7 22” Red, 2 Gauge, 5/16” Ring – 5/16” Ring

8 36” Red, 2 Gauge, 5/16” Ring – 5/16” Ring




Part No. Description Qty.

B01-10-0330 200 Amp Fuse 1

B01-10-0331 Fuse Holder 1

0096-0001 Cap Screw, M6 x 16 2

0096-0039 Hex Nut, Self-Locking, M6 2

B01-06-0058 Contactor – Sevcon 24v DC 100 amp 1

64

DRIVE AND SET ASSEMBLY

65

DRIVE AND SET ASSEMBLY PARTS LIST


1 A-00901L Drive & Set Weldment – Left 1

2 A-00901R Drive & Set Weldment – Right (Not Pictured) 1

3 A-00906 Drive & Set Cylinder 2

4 A-00907-1 Drive & Set Fender Mount – Left 1

5 A-00907-2 Drive & Set Fender Mount – Right (Not Pictured) 1

6 A-00908L D & S Fender Mount Rear – Left 1

7 A-00908R D & S Fender Mount, Rear – Right (Not Pictured) 1

8 A-00143 Fender 2

9 A-00927 Pin, 0.75” x 3.25” W/Head 4

10 A-00926 Pin, 0.75” x 2.5” 2

11 A-00017 Pin Retainer, 0.75” 4

12 A-00925 Pin Retainer, 0.75,” Long 2


14 A-00910 D & S Pivot Weldment 2

15 A-00912 D & S Pivot Arm B 2

16 A-00915 Motor, Hydraulic, Medium Duty – D&S 2

17 A-00920 Friction Wheel Weldment 2

18 0096-0133 Cap Screw, M10 x 65 6

19 0096-0022 Cap Screw, M12 x 75 8

20 0096-0014 Cap Screw, M10 x 20 22



23 Cap Screw, 5/8-18 x 1” 2

24 0090-0788 Washer, Flat, 5/8 2

Not Pictured

A-00932 Manifold Cover 2

A-00235 Power Unit, Drive & Set 1

A-00928 Manifold, Drive & Set 1

A-01937 Brake Cable Assembly – Drive & Set 1

A-01943 Battery Cable Kit – Supplemental – Drive & Set 1

A-01931 Control Box – Platform – Drive & Set 1

66

ORDERING REPLACEMENT PARTS

To order replacement parts, contact the Haulotte Group | BilJax Service Department by phone at 800-537-0540, by fax at 419-446-8202 or by email at [email protected].

For swift service, always have the part number available, as well as the equipment model and serial number. When ordering parts by fax or email, always provide the above information.

QUICK REFERENCE

Equipment Model: Haulotte Group | BilJax 3522A Articulating Boom Lift

Serial Number: ______________________________________________

NOTES

67

NOTES

125 Taylor Parkway Archbold, OH 43502 Phone (419) 445-8915 (800) 537-0540 Fax (419) 445-0367

Distributed by:

Documents

PARTS MANUAL - BilJax · PARTS MANUAL B33-01-0094-05 . BOOM PERSONNEL LIFT This equipment is designed and manufactured in compliance ... Front Rest …